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1 4. Install louver assembly to ensure moisture shed from flashings. 5. Secure louver frames in openings with concealed fasteners. 6. Install perimeter sealant around louver. 7. Contractor shall maintain minimum distances from air intakes to plumbing vents and/or exhaust openings as specified in International Mechanical code and local codes having jurisdiction. END OF SECTION P:\09PROJECTS\09096HYA-MIA\WP\SPECS\CITY OF MIAMI SPECS\DIV 15\15936-AIR INLETS AND OUTLETS.DOCX Air Inlets and Outlets Central Chilled Water Plant and Cooling Tower Design Section

2 SECTION METERS AND GAUGES FOR HVAC AND PLUMBING PART 1 - GENERAL 1.1 SCOPE OF WORK A. Included in this section are: 1. Thermometers for Pipes 2. Thermometers for Ducts 3. Pressure Gauges for Pipes 4. Test Plugs for Pipes 1.2 CODES AND STANDARDS (USE LATEST ADDITION) A. American Recovery and Reinvestment Act (ARRA) of 2009 Section 1605 Required Use of American Iron, Steel, and Manufactured Goods (applies to BASE BID A only) B. American Society of Mechanical Engineers (ASME) 1.3 SUBMITTALS 1. ASME B Pressure Gauges and Gauge Attachments 2. ASME B Thermometers, Direct Reading and Remote Reading 3. ASME B40.3 Bimetallic Actuated Thermometers A. Product Data: For each type of product indicated provide manufacturer s literature. B. Provide certificate indicating compliance with ARRA See Exhibit for sample certificate. This applies to Base Bid A only. C. Shop Drawings: Schedule for instrumentation indicating manufacturer s number, scale range, and location for each. D. Operations and Maintenance Data: Submit under provisions of Division 1. Accurately record location of all instrumentation. PART 2 - PRODUCTS 2.1 LIQUID-IN-GLASS THERMOMETERS FOR PIPES A. Acceptable Manufacturers 1. Ashcroft Inc. 2. H.O. Trerice Company 3. Miljoco Corporation 4. Weiss Instruments, Inc. B. Direct reading liquid-in-glass thermometer complying with ASME B Case: Die-cast aluminum, 9 long 2. Tube: Red or blue colored spirit (organic) filled, lens front 3. Tube Background: Aluminum white with permanently etched scale calibration in degrees Fahrenheit 4. Window: Clear acrylic or glass; provide glass for steam and condensate applications 5. Connector: Adjustable angle joint with positive locking device 6. Stem: Brass of length to suit installation Meters and Gauges for HVAC & Plumbing Central Chilled Water Plant and Cooling Tower Design Section

3 7. Accuracy: ±1 scale division 8. Thermowells: Brass, pressure-tight, socket-type fitting made for insertion into piping and of type, diameter, and length required to hold thermometer clear of any pipe insulation. 9. Basis of Design: H.O. Trerice Company Model AX BIMETALLIC-ACTUATED DIAL THERMOMETERS FOR DUCTS A. Acceptable Manufacturers 1. Ashcroft Inc. 2. H.O. Trerice Co. 3. Miljoco Corporation 4. Weiss Instruments, Inc. B. Direct mounting, bimetallic actuated dial thermometer complying with ASME B Case: 5 diameter dial in stainless steel 2. Element: Bimetallic helix actuated with silicone fluid damping 3. Dial and Pointer: White dialface calibrated in degrees F with black markings and black pointer 4. Window: Hermetically sealed glass lens 5. Connector: Adjustable angle with front recalibration 6. Stem: Stainless steel stem of length to suit installation with zinc plated steel mounting flange for fastening to sheet metal duct 7. Accuracy: ±1% of full scale 8. Basis of Design: H.O. Trerice Company Model B PRESSURE GAUGES FOR PIPES A. Acceptable Manufacturers 1. Ashcroft Inc. 2. H.O. Trerice Co. 3. Miljoco Corporation 4. Weiss Instruments, Inc. B. Dial type pressure gauge complying with ASME B Case: 4½ diameter black aluminum 2. Pressure Element Assembly: Bronze bourdon tube 3. Pressure Connection: Brass socket 4. Movement: Rotary stainless steel 5. Dial: Aluminum with permanently etched black scale calibrated in psi on white background 6. Window: Clear glass 7. Accuracy: ±0.5% percent of full scale 8. Basis of Design: H.O. Trerice Company Model 500XB C. Pressure Gauge Accessories 1. Valves a. ¼ NPT brass needle valve for a maximum pressure of 2,000 psig b. Basis of Design: H.O. Trerice Company Series Impulse Dampeners a. Brass with ¼ NPT connection Meters and Gauges for HVAC and Plumbing Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

4 b. Basis of Design: H.O. Trerice Company Series Coil Syphons 2.4 TEST PLUGS FOR PIPES a. Seamless brass, schedule 40, ¼ NPT connections b. H.O. Trerice Company Series 885 A. Acceptable Manufacturers 1. Petersen Products Co. 2. Sisco Manufacturing Company, Inc. 3. H.O. Trerice Company 4. Watts Water Technologies B. Test Plug (for uninsulated pipe) 1. ¼ by 1½ long brass fitting for receiving ⅛ outside diameter pressure or temperature probe a. Core inserts: Two self-sealing rubber valve cores with a color coded cap strap with gasket (1) Neoprene (maximum 200F) at 500 psi (2) Nordel (maximum 275F) at 500 psi b. Minimum Pressure and Temperature Rating: 1000 psi at 140F c. Basis of Design: Model 100 (neoprene core) or Model 110 (Nordel core) manufactured by Petersen Products Co. C. Test Plug (for insulated pipe) 1. ¼ by 3 long brass fitting for receiving ⅛ outside diameter pressure or temperature probe a. Core Inserts: Two self-sealing rubber valve cores with a color coded cap strap with gasket (1) Neoprene (maximum 200F) at 500 psi (2) Nordel (maximum 275F) at 500 psi b. Minimum Pressure and Temperature Rating: 1,000 psi at 140F c. Basis of Design: Model 100XL (neoprene core) or Model 110XL (Nordel core) manufactured by Petersen Products Co. 2.5 HYDRONIC INDICATION SYSTEM (COMPOUND PRESSURE GAUGE AND TRUMPET VALVE) A. Acceptable Manufacturers: 1. Flow Conditioning Corp. B. Hydronic indication systems shall consist of hydronic indicator (compound gauge) and four-port trumpet valve model TV-4 by Flow Conditioning Corp. 1. Hydronic indicator shall have 1% accuracy. Steel case shall be 4-1/2", stem mounted with screwed ring and crystal. Indicator shall have re-calibrator, compound scale calibrated in psi and feet from full vacuum to selected pressure and quick set dial for pressure comparison. Maximum indicator pressure shall exceed pump working pressure by minimum 50 psi. Meters and Gauges for HVAC & Plumbing Central Chilled Water Plant and Cooling Tower Design Section

5 2. Trumpet valve shall have spring return push button manifold of rugged brass construction with ports for connection to system at indicated points and with test connection for gauge calibration. PART 3 - EXECUTION 3.1 APPLICATIONS A. Pressure Gauges 1. Provide pressure gauges in locations indicated on drawings with a scale range of those shown below such that the range is between 1 ½ and 2 times two times the operating pressure of the system. B. Thermometers 3.2 INSTALLATION a psi b psi c psi d psi e psi f psi g psi h psi C. Install liquid-in-glass thermometers in all chilled water, hot water, condenser water, steam and condensate piping applications in locations shown on drawings and with ranges as shown in the following table: System Range (degrees F) Heating hot water 30F to 240F with 2F scale divisions Chilled water 0F to 100F with 1F scale divisions Condenser water 0F to 160F with 2F scale divisions. D. Install bimetallic-actuated dial thermometers with range of -40F to 110F with 2F scale divisions in air ducts in the following locations: 1. Outside air intake ducts or plenums 2. Return air ducts 3. Mixed air ducts or plenums A. Install in accordance with manufacturer s instructions. B. Install gauges and thermometers in locations where they are easily read from normal operating level. C. Thermometers for Pipes 1. Install direct-mounting thermometers and adjust vertical and tilted positions. 2. Install thermometers in piping systems in thermowells with socket extending to center of pipe or a minimum of 2 into fluid for piping less than 4. Enlarge pipes smaller than 2½ for installation of thermowells. D. Thermometers for Ducts 1. Install direct-mounting thermometers and adjust vertical and tilted positions. Meters and Gauges for HVAC and Plumbing Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

6 2. Install thermometers in air duct systems on flanges and attach to duct with screws. E. Pressure Gauges for Pipes 1. Install direct-mounting pressure gauges in piping tees with pressure gauge located on pipe at most readable position. 2. Provide needle valve and impulse dampener for each pressure gauge installed in pipe carrying all fluids except steam. 3. Provide needle valve and coil siphon fitting for each pressure gauge installed in pipe carrying steam. F. Install test plugs in tees in piping where indicated. G. Hydronic Indication System for Pumps 1. Install hydronic indication system on pumps as indicated on drawings. 2. Hydronic indication system shall be reliably and permanently attached to piping with heavy bracket at convenient height. Connect the system to the following ports: a. Upstream of strainer/suction diffuser b. Downstream of strainer/suction diffuser (pump inlet). c. Pump discharge d. Downstream of discharge isolation valve END OF SECTION P:\09PROJECTS\09096HYA-MIA\WP\SPECS\CITY OF MIAMI SPECS\DIV 15\15980-METERS AND GAUGES FOR HVAC & PLUMBING.DOCX Meters and Gauges for HVAC & Plumbing Central Chilled Water Plant and Cooling Tower Design Section

7 SECTION REFRIGERANT DETECTION SYSTEM PART 1 - GENERAL 1.1 SCOPE OF WORK A. Systems addressed in this section include the following: 1. Refrigerant detection system. B. Products/Materials provided by others: 1.2 DEFINITIONS Not applicable. 1. Control wiring. 2. Power wiring. 1.3 CODES AND STANDARDS A. American Recovery and Reinvestment Act (ARRA) of 2009 Section 1605 Required Use of American Iron, Steel, and Manufactured Goods (applies to BASE BID A only) B. ANSI/ASHRAE Standard Safety Standard for Refrigeration Systems. 1.4 QUALITY ASSURANCE Not applicable. 1.5 SUBMITTALS A. Product Data: 1. Provide manufacturer s detailed product literature and illustrations for all components. 2. Provide cross-sensitivity response data to other refrigerants as well as cleaning agents and solvents typically found in chiller equipment rooms. B. Provide certificate indicating compliance with ARRA See Exhibit for sample certificate. This applies to Base Bid A only. C. Provide manufacturer s installation instructions with Product Data. 1.6 DELIVERY, STORAGE AND HANDLING Not applicable. 1.7 SPARE PARTS A. Provide one (1) extra set of end-of-line filters and zero filter. 1.8 WARRANTY A. Provide one year parts and service warranty. 1.9 MAINTENANCE Not applicable. PART 2 - PRODUCTS 2.1 REFRIGERANT DETECTION SYSTEM Refrigerant Detection System Central Chilled Water Plant and Cooling Tower Design Section

8 A. Acceptable Manufacturers: 1. Mine Safety Appliances (MSA) Chillgard 2. O-I Analytical SAM 3. Bacharach HGM 4. Vulcain VA-SQN 5. Thermal Gas Systems Haloguard IR B. Refrigerant gas detection system supplier and installer shall be familiar with standard practices of safety and installation for refrigerant vapor detection systems and shall provide these systems as a normal course of business. C. System shall meet or exceed the latest ASHRAE Standard 15 requirements and EPA Standard 608 CFR. System shall incorporate all latest revisions to bring up to current standards. D. System shall utilize multi-point monitoring with sequential sampling. 1. System shall be capable of detecting the presence of any CFC, HCFC, HFC, or ammonia refrigerant, regardless of which particular refrigerants are selected (e.g., R-11, R-12, R-22, R-123, R-134a, etc.). 2. Oxygen deficiency monitoring is not acceptable 3. System shall be capable of indicating, alarming, initiating purge/vent, and shutting down equipment as specified below and in governing regulations. E. Control Panel and Equipment 1. Analyzer: a. Shall be microprocessor-based and employ photoacoustic infrared or pyroelectric infrared sensor technology. b. Electrochemical sensing technology employing depletion sensors and short term life sensors which deplete, poison, or consume as a normal part of their operation or storage shelf life shall not be acceptable. c. Analyzer shall respond to the target refrigerant only and will not sense, display, or false alarm to any interfering gases, including other refrigerants. d. The analyzer and sensor combination shall be compound-specific, and/or capable of monitoring multiple compounds and be calibrated for specific refrigerant R-11, R-12, R-22, R-123, R-134a or other as required by the installed refrigerants. e. Refrigerant selection for each channel of multiple-channel analyzers shall be independently selectable. f. Unit can be switched to monitor, at a future date, a different refrigerant type by changing one part and recalibrating (e.g., CFC-11 to HCFC-123, etc.). g. Accuracy shall be ±1 part per million (ppm) in the range of 0-50 ppm, and ±10% of reading in the range of ppm. Accuracy shall include the effects of all errors including, but not limited to, linearity, stability, sensitivity, temperature effects, and humidity effects. (1) Submit calculations and supporting data indicating compliance with this requirement. h. Minimum concentration sensed shall be no greater than 5 ppm. Refrigerant Detection System Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

9 i. Auto-zero calibration shall be initiated at one hour intervals (adjustable), or manually, with air from an uncontaminated air source. j. Analysis response time shall be 70 seconds to a 90% step change in concentration when sequencer is switched to the sample. k. No field calibration shall be required for start-up or during the first year of operation. 2. Display: a. Provide alphanumeric green backlit LCD display, ½ figures, lowenergy level type, easily visible across darkened mechanical room. b. Display shall automatically scroll concentration levels for each sample point and alternately display any alarm or malfunction messages without operator-initiated keypad intervention. c. Alarm display shall alternately annunciate and define each alarm by sample point zone and alarm level. 3. Diagnostics: a. Provide self-diagnostics with on-board malfunction data log and a malfunction contact for remote annunciation at the building automation system (BAS). b. Display flow loss of sample, ZERO line, and electrical malfunction. 4. Sequential Sampling System: a. Multi-point sequential sampling system shall be integrated into analyzer enclosure. b. Microprocessor shall sequentially control required flow valves and coordinate signals to monitor from remote sampling locations. c. Built-in sample pump for continuous sample draw with differential pressure flow switch for low flow indication. d. Sample draw line capability shall be not less than 500 feet excluding exhaust tubing. e. Each point shall have adjustable sampling time for various tubing lengths and adjustable levels of alarm. f. The monitor shall have add-on sample point expansion modules available for present configuration and for future expansion. Expansion modules for future expansion are to be provided. g. Provide the number of sampling points as shown on the Drawings. h. The maximum recycle time (i.e., time when sequencer begins sampling of point #1, until it begins sampling of point #1 in the next cycle) shall be as follows, based on eight channels: 5. Enclosure: 50-foot sample tube length, each point 100-foot sample tube length, each point Less than 4 minutes Less than 6 minutes (1) Submit calculations and supporting data indicating compliance with this requirement. (2) Multiple refrigerant detection systems may be provided in order to meet the maximum recycle time at no additional cost to Owner. Refrigerant Detection System Central Chilled Water Plant and Cooling Tower Design Section

10 a. Wall-mounted enclosure with no external keypads for tampering. b. Power supply shall have multiple-tap isolating transformer, on/off switch, and circuit breaker, and shall require no more than 75 watts (main unit and expansion units combined). 6. Alarms and Other Outputs: a. Dry alarm contacts: (1) Provide three independent dry alarm contacts, each rated for 5 amp., 120 VAC. (2) Contacts shall be field-selectable as follows: (a) Normally open (NO) or normally closed (NC) (b) Latched (manual reset) / Non-latched (auto reset) b. Provide three independently-adjustable levels of alarm for each sampling point. c. Provide a separate 4-20 ma DC analog output for each sampling point representing the refrigerant levels in parts per million (ppm). Multiplexing may be used in lieu of independent outputs when five (5) or more sample points are provided by the same system. d. Provide an RS-485 output to communicate all refrigerant levels to a building automation system (BAS) for centralized facility data logging and trending. F. Strobe Light and Alarm Horn: 1. Strobe Light: 15 candela strobe light or rotating beacon. 2. Alarm Horn: minimum of 72 dba at 10 feet. 3. Shall be UL or CSA listed. 4. Where located outdoors, unit shall be weatherproof and listed for outdoor use over a temperature range of -30F to 150F for all humidity levels. G. Description of Operation: 1. The three independent dry alarm contacts shall represent low, medium, and high alarm levels. 2. The low alarm shall be triggered whenever the gas concentration in any of the sampling points exceeds its respective low alarm level setpoint. a. The low alarm shall be an early leak warning alarm. b. Setpoint shall be set at 10 ppm, regardless of refrigerant type, to prevent eventual refrigerant loss. 3. The medium alarm shall be triggered whenever the gas concentration in any of the sampling points exceeds its respective medium alarm level setpoint. a. The medium alarm shall be a spill alarm. b. Shall energize the strobe light(s) and activates the exhaust fan in purge mode. c. Shall be manually reset at the monitor reset button. d. Setpoint shall be set at 25 ppm for R-123 and 300 ppm for all other refrigerants. 4. The high alarm shall be triggered whenever the gas concentration in any of the sampling points exceeds its respective high alarm level setpoint. Refrigerant Detection System Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

11 a. The high alarm shall be an evacuate alarm. b. Shall energize the strobe light(s) and the alarm horn(s), activates the exhaust fan in purge mode. c. Program alarm horn audio to be a different sound than other life safety alarm systems (e.g., fire alarm). d. Shall be manually reset at the monitor reset button. e. Setpoint shall be set at 50 ppm for R-123 and 500 ppm for all other refrigerants. H. Maintenance and Calibration: 1. No calibration shall be required for a period of one year from date of shipment. 2. Zero filter and end-of-line filters shall be included with initial system. 3. Systems which frequently generate nuisance alarms, do not meet recycle times, or which require frequent calibration or sensor replacement during the first two operating years will be replaced in their entirety by Contractor at no additional cost to Owner. PART 3 - EXECUTION 3.1 INSTALLATION A. Install in accordance with manufacturer s instructions. 3.2 SAMPLE TUBING A. Shall be ¼ O.D. seamless Type ACR (hard or annealed) complying with ASTM-B280 or seamless Type K, L or M (drawn or annealed) in accordance with ASTM-B88. B. Shall be installed in good workmanship manner and shall be field assembled with compression fittings. Soldered or brazed connections are not acceptable because of foreign gases, masses, and compounds introduced. C. Poly or other absorbing and leaching tubing is not acceptable as it corrupts actual sampled air. D. All bends shall have a minimum bend radius of not less than 5. E. Install in accordance with latest ASHRAE Standards and local building codes. Support at intervals no greater than 6 feet and at all bends. 3.3 LOCATION AND TERMINATION A. Tubing shall be field assembled with compression fittings and shall terminate 12 to 18 above floor level with 0.1 micron particulate/coalescent filters furnished by the monitor manufacturer. B. Locate sensing terminations downwind of the device to be monitored, in the direction of convection airflow, and where shown on the Drawings. Run in areas not subject to damage. C. Identify all sample tubing, both ends, with stamped (non-ferrous) metal tags labeling by both zone and chiller monitored. D. Control wiring shall be provided by the control contractor; power wiring by the electric contractor. 3.4 COMMISSIONING AND START-UP A. Unit must be factory calibrated. No field calibration is acceptable at time of installation. Refrigerant Detection System Central Chilled Water Plant and Cooling Tower Design Section

12 B. Conduct the complete installation and start-up in accordance with the manufacturer=s recommendations. Become familiar with the manufacturer s complete instruction book. 3.5 TRAINING A. Provide a minimum of one hour of instruction to Owner s authorized operating personnel in the proper operation and maintenance of the system. B. If monitor requires key strokes and/or programming to query information in normal daily operation, conduct additional programming instruction to Owner s satisfaction at no additional cost to Owner. C. Provide three hard copies of operating and maintenance instructions to Owner s designated representative. END OF SECTION P:\09PROJECTS\09096HYA-MIA\WP\SPECS\CITY OF MIAMI SPECS\DIV 15\15981-REFRIGERANT DETECTION SYSTEM.DOCX Refrigerant Detection System Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

13 SECTION TESTING, ADJUSTING, AND BALANCING FOR HVAC PART 1 - GENERAL 1.1 SCOPE OF WORK A. This Section includes TAB to produce design objectives for the following: 1.2 DEFINITIONS 1. Air Systems: a. Constant-volume air systems. 2. Hydronic Piping Systems: a. Variable-flow systems. b. Primary-secondary systems. 3. HVAC equipment quantitative-performance settings. 4. Verifying that automatic control devices are functioning properly. 5. Reporting results of activities and procedures specified in this Section. A. Adjust: To regulate fluid flow rate and air patterns at the terminal equipment, such as to reduce fan speed or adjust a damper. B. Balance: To proportion flows within the distribution system, including submains, branches, and terminals, according to indicated quantities. C. Barrier or Boundary: Construction, either vertical or horizontal, such as walls, floors, and ceilings that are designed and constructed to restrict the movement of airflow, smoke, odors, and other pollutants. D. Draft: A current of air, when referring to localized effect caused by one or more factors of high air velocity, low ambient temperature, or direction of airflow, whereby more heat is withdrawn from a person s skin than is normally dissipated. E. NC: Noise criteria. F. Procedure: An approach to and execution of a sequence of work operations to yield repeatable results. G. RC: Room criteria. H. Report Forms: Test data sheets for recording test data in logical order. I. Stair Pressurization System: A type of smoke-control system that is intended to positively pressurize stair towers with outdoor air by using fans to keep smoke from contaminating the stair towers during an alarm condition. J. Static Head: The pressure due to the weight of the fluid above the point of measurement. In a closed system, static head is equal on both sides of the pump. K. Suction Head: The height of fluid surface above the centerline of the pump on the suction side. L. System Effect: A phenomenon that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section

14 M. System Effect Factors: Allowances used to calculate a reduction of the performance ratings of a fan when installed under conditions different from those presented when the fan was performance tested. N. TAB: Testing, adjusting, and balancing. O. Terminal: A point where the controlled medium, such as fluid or energy, enters or leaves the distribution system. P. Test: A procedure to determine quantitative performance of systems or equipment. Q. Testing, Adjusting, and Balancing (TAB) Firm: The entity responsible for performing and reporting TAB procedures. 1.3 REFERENCES A. American Recovery and Reinvestment Act of 2009 (applies to Base Bid A only) 1. Section 1512 Reporting and Registration Requirements 2. Section Required Use of American Iron, Steel, and Manufactured Goods 3. Section 1606 Wage Rate Requirements B. Davis- Bacon Act applicable sections (applies to both Base Bids) 1.4 SUBMITTALS A. Certified TAB Reports: Submit two copies of reports prepared, as specified in this Section, on approved forms certified by TAB firm. B. Warranties specified in this Section. 1.5 QUALITY ASSURANCE A. TAB Firm Qualifications: Engage a TAB firm certified by AABC, NEBB, or TABB. B. Certification of TAB Reports: Certify TAB field data reports. This certification includes the following: 1. Review field data reports to validate accuracy of data and to prepare certified TAB reports. 2. Certify that TAB team complied with approved TAB plan and the procedures specified and referenced in this Specification. C. TAB Report Forms: Use standard forms from AABC, NEBB or TABB/SMACNA. D. Instrumentation Type, Quantity, and Accuracy: As described in AABC s National Standards for Total System Balance, NEBB s Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems, Section II, Required Instrumentation for NEBB Certification, or the TABB Instrument List. E. Instrumentation Calibration: Calibrate instruments at least every six months or more frequently if required by instrument manufacturer. 1.6 COORDINATION 1. Keep an updated record of instrument calibration that indicates date of calibration and the name of party performing instrument calibration. A. Coordinate the efforts of factory-authorized service representatives for systems and equipment, HVAC controls installers, and other mechanics to operate HVAC systems and equipment to support and assist TAB activities. B. Notice: Provide seven days advance notice for each test. Include scheduled test dates and times. Testing, Adjusting and Balancing for HVAC Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

15 C. Perform TAB after leakage and pressure tests on air and water distribution systems have been satisfactorily completed. 1.7 WARRANTY A. Provide one of the following performance guarantees: 1. AABC National Project Performance Guarantee 2. NEBB Certificate of Conformance Certification 3. TABB Quality Assurance Program Guarantee B. Guarantee shall include the following provisions: 1. The certified TAB firm has tested and balanced systems according to the Contract Documents. 2. Systems are balanced to optimum performance capabilities within design and installation limits. PART 2 - PRODUCTS 2.1 NOT USED PART 3 - EXECUTION 3.1 EXAMINATION A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems designs that may preclude proper TAB of systems and equipment. 1. Contract Documents are defined in the General and Supplementary Conditions of Contract. 2. Verify that balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers, are required by the Contract Documents. Verify that quantities and locations of these balancing devices are accessible and appropriate for effective balancing and for efficient system and equipment operation. B. Examine approved submittal data of HVAC systems and equipment. C. Examine Project Record Documents described in Section Project Closeout. D. Examine design data, including HVAC system descriptions, statements of design assumptions for environmental conditions and systems output, and statements of philosophies and assumptions about HVAC system and equipment controls. E. Examine equipment performance data including fan and pump curves. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system. Calculate system effect factors to reduce performance ratings of HVAC equipment when installed under conditions different from those presented when the equipment was performance tested at the factory. To calculate system effects for air systems, use tables and charts found in AMCA 201, Fans and Systems, Sections 7 through 10; or in SMACNA s HVAC Systems--Duct Design, Sections 5 and 6. Compare this data with the design data and installed conditions. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section

16 F. Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Sections have been performed. G. Examine system and equipment test reports. H. Examine HVAC system and equipment installations to verify that indicated balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers, are properly installed, and that their locations are accessible and appropriate for effective balancing and for efficient system and equipment operation. I. Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing. J. Examine HVAC equipment to ensure that clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. K. Examine strainers for clean screens and proper perforations. L. Examine heat-transfer coils for correct piping connections and for clean and straight fins. M. Examine system pumps to ensure absence of entrained air in the suction piping. N. Examine equipment for installation and for properly operating safety interlocks and controls. O. Examine automatic temperature system components to verify the following: 1. Dampers, valves, and other controlled devices are operated by the intended controller. 2. Dampers and valves are in the position indicated by the controller. 3. Integrity of valves and dampers for free and full operation and for tightness of fully closed and fully open positions. 4. Automatic modulating and shutoff valves, including two-way valves and threeway mixing and diverting valves, are properly connected. 5. Thermostats and humidistats are located to avoid adverse effects of sunlight, drafts, and cold walls. 6. Sensors are located to sense only the intended conditions. 7. Sequence of operation for control modes is according to the Contract Documents. 8. Controller set points are set at indicated values. 9. Interlocked systems are operating. P. Report deficiencies discovered before and during performance of TAB procedures. Observe and record system reactions to changes in conditions. Record default set points if different from indicated values. 3.2 PREPARATION A. Prepare a TAB plan that includes strategies and step-by-step procedures. B. Complete system readiness checks and prepare system readiness reports. Verify the following: 1. Permanent electrical power wiring is complete. 2. Hydronic systems are filled, clean, and free of air. 3. Automatic temperature-control systems are operational. 4. Equipment and duct access doors are securely closed. Testing, Adjusting and Balancing for HVAC Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

17 5. Balance, smoke, and fire dampers are open. 6. Isolating and balancing valves are open and control valves are operational. 7. Ceilings are installed in critical areas where air-pattern adjustments are required and access to balancing devices is provided. 8. Windows and doors can be closed so indicated conditions for system operations can be met. 3.3 GENERAL PROCEDURES FOR TESTING AND BALANCING A. Perform testing and balancing procedures on each system according to the procedures contained in AABC s National Standards for Total System Balance, NEBB s Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems, or SMACNA s HVAC Systems - Testing, Adjusting, and Balancing and this Section. B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary to allow adequate performance of procedures. After testing and balancing, close probe holes and patch insulation with new materials identical to those removed. Restore vapor barrier and finish according to insulation Specifications for this Project. C. Mark equipment and balancing device settings with paint or other suitable, permanent identification material, including damper-control positions, valve position indicators, fan-speed-control levers, and similar controls and devices, to show final settings. D. Take and report testing and balancing measurements in inch-pound (IP) units. 3.4 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS A. Prepare test reports for both fans and outlets. Obtain manufacturer s outlet factors and recommended testing procedures. Crosscheck the summation of required outlet volumes with required fan volumes. B. Determine the best locations in main and branch ducts for accurate duct airflow measurements. C. Check airflow patterns from the outside-air louvers and dampers and the return- and exhaust-air dampers, through the supply-fan discharge and mixing dampers. D. Locate start-stop and disconnect switches, electrical interlocks, and motor starters. E. Verify that motor starters are equipped with properly sized thermal protection. F. Check dampers for proper position to achieve desired airflow path. G. Check for airflow blockages. H. Check condensate drains for proper connections and functioning. I. Check for proper sealing of air-handling unit components. J. Check for proper sealing of air duct system. 3.5 PROCEDURES FOR CONSTANT-VOLUME AIR SYSTEMS A. Adjust fans to deliver total indicated airflows within the maximum allowable fan speed listed by fan manufacturer. 1. Measure fan static pressures to determine actual static pressure as follows: a. Measure outlet static pressure as far downstream from the fan as practicable and upstream from restrictions in ducts such as elbows and transitions. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section

18 b. Measure static pressure directly at the fan outlet or through the flexible connection. c. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as possible, upstream from flexible connection and downstream from duct restrictions. d. Measure inlet static pressure of double-inlet fans through the wall of the plenum that houses the fan. 2. Measure static pressure across each component that makes up an air-handling unit, rooftop unit, and other air-handling and -treating equipment. a. Simulate dirty filter operation and record the point at which maintenance personnel must change filters. 3. Measure static pressures entering and leaving other devices such as sound traps, heat recovery equipment, and air washers, under final balanced conditions. 4. Compare design data with installed conditions to determine variations in design static pressures versus actual static pressures. Compare actual system effect factors with calculated system effect factors to identify where variations occur. Recommend corrective action to align design and actual conditions. 5. Obtain approval from Engineer for adjustment of fan speed higher or lower than indicated speed. Make required adjustments to pulley sizes, motor sizes, and electrical connections to accommodate fan-speed changes. 6. Do not make fan-speed adjustments that result in motor overload. Consult equipment manufacturers about fan-speed safety factors. Modulate dampers and measure fan-motor amperage to ensure that no overload will occur. Measure amperage in full cooling, full heating, economizer, and any other operating modes to determine the maximum required brake horsepower. 7. Make required adjustments to vane axial fan blade pitch angle to achieve required airflow. 8. Provide sheaves, pulleys and belts required for adjustment of fan speed. B. Adjust volume dampers for main duct, submain ducts, and major branch ducts to indicated airflows within specified tolerances. 1. Measure static pressure at a point downstream from the balancing damper and adjust volume dampers until the proper static pressure is achieved. a. Where sufficient space in submain and branch ducts is unavailable for Pitot-tube traverse measurements, measure airflow at terminal outlets and inlets and calculate the total airflow for that zone. 2. Remeasure each submain and branch duct after all have been adjusted. Continue to adjust submain and branch ducts to indicated airflows within specified tolerances. C. Measure terminal outlets and inlets without making adjustments. 1. Measure terminal outlets using a direct-reading hood or outlet manufacturer s written instructions and calculating factors. D. Adjust terminal outlets and inlets for each space to indicated airflows within specified tolerances of indicated values. Make adjustments using volume dampers rather than extractors and the dampers at air terminals. Testing, Adjusting and Balancing for HVAC Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

19 1. Adjust each outlet in same room or space to within specified tolerances of indicated quantities without generating noise levels above the limitations prescribed by the Contract Documents. 2. Adjust patterns of adjustable outlets for proper distribution without drafts. 3.6 GENERAL PROCEDURES FOR HYDRONIC SYSTEMS A. Prepare test reports with pertinent design data and number in sequence starting at pump to end of system. Check the sum of branch-circuit flows against approved pump flow rate. Correct variations that exceed plus or minus 5 percent. B. Prepare schematic diagrams of systems as-built piping layouts. C. Prepare hydronic systems for testing and balancing according to the following, in addition to the general preparation procedures specified above: 1. Open all manual valves for maximum flow. 2. Check expansion tank liquid level. 3. Check makeup-water-station pressure gage for adequate pressure for highest vent. 4. Check flow-control valves for specified sequence of operation and set at indicated flow. 5. Set differential-pressure control valves at the specified differential pressure. Do not set at fully closed position when pump is positive-displacement type unless several terminal valves are kept open. 6. Set system controls so automatic valves are wide open to heat exchangers. 7. Check pump-motor load. If motor is overloaded, throttle main flow-balancing device so motor nameplate rating is not exceeded. 8. Check air vents for a forceful liquid flow exiting from vents when manually operated. 3.7 PROCEDURES FOR HYDRONIC SYSTEMS A. Measure water flow at pumps. Use the following procedures, except for positivedisplacement pumps: 1. Verify impeller size by operating the pump with the discharge valve closed. Read pressure differential across the pump. Convert pressure to head and correct for differences in gage heights. Note the point on manufacturer s pump curve at zero flow and verify that the pump has the intended impeller size. 2. Check system resistance. With all valves open, read pressure differential across the pump and mark pump manufacturer s head-capacity curve. Adjust pump discharge valve until indicated water flow is achieved. 3. Verify pump-motor brake horsepower. Calculate the intended brake horsepower for the system based on pump manufacturer s performance data. Compare calculated brake horsepower with nameplate data on the pump motor. Report conditions where actual amperage exceeds motor nameplate amperage. 4. Report flow rates that are not within plus or minus 5 percent of design. B. Set calibrated balancing valves, if installed, at calculated presettings. C. Measure flow at all stations and adjust, where necessary, to obtain first balance. 1. System components that have Cv rating or an accurately cataloged flowpressure-drop relationship may be used as a flow-indicating device. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section

20 D. Measure flow at main balancing station and set main balancing device to achieve flow that is 5 percent greater than indicated flow. E. Adjust balancing stations to within specified tolerances of indicated flow rate as follows: 1. Determine the balancing station with the highest percentage over indicated flow. 2. Adjust each station in turn, beginning with the station with the highest percentage over indicated flow and proceeding to the station with the lowest percentage over indicated flow. 3. Record settings and mark balancing devices. F. Measure pump flow rate and make final measurements of pump amperage, voltage, rpm, pump heads, and systems pressures and temperatures including outdoor-air temperature. G. Measure the differential-pressure control valve settings existing at the conclusions of balancing. H. When the balanced pump discharge valve position is greater than 45 percent closed, the pump impeller shall be trimmed or replaced. Calculate the required impeller size and notify the Engineer and Contractor. The Contractor shall furnish and install the new impeller. Once the new impeller is installed, measure pump flow rate and set discharge valve to achieve flow that is 5 percent greater than indicated flow. Make final measurements of pump flow, shutoff head, suction and discharge pressures, rpm, voltage and amperage. 3.8 PROCEDURES FOR VARIABLE-FLOW HYDRONIC SYSTEMS A. Balance systems with automatic two- and three-way control valves by setting systems at maximum flow through heat-exchange terminals and proceed as specified above for hydronic systems. B. Once the full flow condition is balanced and the system differential pressure setpoint is established, to control the variable speed pumps, observe the flow on the circuit with the greatest resistance as the other circuits are closed one at a time. The flow in the observed circuit should remain equal to, or greater than, the previously set flow. 3.9 PROCEDURES FOR PRIMARY-SECONDARY-FLOW HYDRONIC SYSTEMS A. Balance the primary system crossover flow first, then balance the secondary system PROCEDURES FOR HEAT EXCHANGERS A. Measure water flow through all circuits. B. Adjust water flow to within specified tolerances. C. Measure inlet and outlet water temperatures. D. Check the setting and operation of safety and relief valves. Record settings PROCEDURES FOR MOTORS A. Motors, ½ HP and Larger: Test at final balanced conditions and record the following data: 1. Manufacturer, model, and serial numbers. 2. Motor horsepower rating. 3. Motor rpm. 4. Efficiency rating. 5. Nameplate and measured voltage, each phase. Testing, Adjusting and Balancing for HVAC Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

21 6. Nameplate and measured amperage, each phase. 7. Starter thermal-protection-element rating. B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass for the controller to prove proper operation. Record observations, including controller manufacturer, model and serial numbers, and nameplate data PROCEDURES FOR CHILLERS A. Balance water flow through each evaporator and condenser to within specified tolerances of indicated flow with all pumps operating. With only one chiller operating in a multiple chiller installation, do not exceed the flow for the maximum tube velocity recommended by the chiller manufacturer. Measure and record the following data with each chiller operating at design conditions: 1. Evaporator-water entering and leaving temperatures, pressure drop, and water flow. 2. If water-cooled chillers, condenser-water entering and leaving temperatures, pressure drop, and water flow. 3. Evaporator and condenser refrigerant temperatures and pressures, using instruments furnished by chiller manufacturer. 4. Power factor if factory-installed instrumentation is furnished for measuring kilowatt. 5. Kilowatt input if factory-installed instrumentation is furnished for measuring kilowatt. 6. Capacity: Calculate in tons of cooling. 7. If air-cooled chillers, verify condenser-fan rotation and record fan and motor data including number of fans and entering- and leaving-air temperatures PROCEDURES FOR COOLING TOWERS A. Shut off makeup water for the duration of the test, and verify that makeup and blowdown systems are fully operational after tests and before leaving the equipment. Perform the following tests and record the results: 1. Measure condenser-water flow to each cell of the cooling tower. 2. Measure entering- and leaving-water temperatures. 3. Measure wet- and dry-bulb temperatures of entering air. 4. Measure wet- and dry-bulb temperatures of leaving air. 5. Measure condenser-water flow rate recirculating through the cooling tower. 6. Measure cooling tower pump discharge pressure. 7. Adjust water level and feed rate of makeup-water system PROCEDURES FOR HEAT-TRANSFER COILS A. Water Coils: Measure the following data for each coil: 1. Entering- and leaving-water temperature. 2. Water flow rate. 3. Water pressure drop. 4. Dry-bulb temperature of entering and leaving air. 5. Wet-bulb temperature of entering and leaving air for cooling coils. 6. Airflow. 7. Air pressure drop. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section

22 3.15 TEMPERATURE-CONTROL VERIFICATION A. Verify that controllers are calibrated and commissioned. B. Check transmitter and controller locations and note conditions that would adversely affect control functions. C. Record controller settings and note variances between set points and actual measurements. D. Check the operation of limiting controllers (i.e., high- and low-temperature controllers). E. Check free travel and proper operation of control devices such as damper and valve operators. F. Check the sequence of operation of control devices. Note air pressures and device positions and correlate with airflow and water flow measurements. Note the speed of response to input changes. G. Check the interaction of electrically operated switch transducers. H. Check the interaction of interlock and lockout systems. I. Check main control supply-air pressure and observe compressor and dryer operations. J. Record voltages of power supply and controller output. Determine whether the system operates on a grounded or ungrounded power supply. K. Note operation of electric actuators using spring return for proper fail-safe operations TOLERANCES A. Adjust main ducts in air handling systems to ± 5% of design parameters for supply and exhaust/return systems. Adjust individual terminals and branches to ± 7.5% of design conditions for supply and exhaust/return systems. For applications where differential pressures must be maintained, use the following criteria: Positively pressurized spaces Supply air... 0 to +10% Exhaust air... 0 to -10% Return air... 0 to -10% Negatively pressurized spaces Supply air... 0 to -10% Exhaust air... 0 to +10% Return air... 0 to +10% B. Please note that differentials between supply and exhaust/return airflows, as indicated in the drawings, indicate those spaces with a requirement for differential pressure to be maintained. C. Adjust hydronic systems to ± 5% of design parameters REPORTING A. Initial Construction-Phase Report: Based on examination of the Contract Documents as specified in Examination Article, prepare a report on the adequacy of design for systems balancing devices. Recommend changes and additions to systems balancing devices to facilitate proper performance measuring and balancing. Recommend changes and additions to HVAC systems and general construction to allow access for performance measuring and balancing devices. Testing, Adjusting and Balancing for HVAC Section Central Chilled Water Plant and Cooling Tower Design October 14, 2011 G/BA #09096

23 B. Status Reports: As Work progresses, prepare reports to describe completed procedures, procedures in progress, and scheduled procedures. Include a list of deficiencies and problems found in systems being tested and balanced. Prepare a separate report for each system and each building floor for systems serving multiple floors FINAL REPORT A. General: Typewritten, or computer printout in letter-quality font, on standard bond paper, in three-ring binder, tabulated and divided into sections by tested and balanced systems. B. Include a certification sheet in front of binder signed and sealed by the certified testing and balancing engineer. 1. Include a list of instruments used for procedures, along with proof of calibration. C. Final Report Contents: In addition to certified field report data, include the following: 1. Pump curves. 2. Fan curves. 3. Manufacturers test data. 4. Field test reports prepared by system and equipment installers. 5. Other information relative to equipment performance, but do not include Shop Drawings and Product Data. D. General Report Data: In addition to form titles and entries, include the following data in the final report, as applicable: 1. Title page. 2. Name and address of TAB firm. 3. Project name. 4. Project location. 5. Architect s name and address. 6. Engineer s name and address. 7. Contractor s name and address. 8. Report date. 9. Signature of TAB firm who certifies the report. 10. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report. 11. Summary of contents including the following: a. Indicated versus final performance. b. Notable characteristics of systems. c. Description of system operation sequence if it varies from the Contract Documents. 12. Nomenclature sheets for each item of equipment. 13. Data for terminal units, including manufacturer, type size, and fittings. 14. Notes to explain why certain final data in the body of reports varies from indicated values. 15. Test conditions for fans and pump performance forms including the following: a. Settings for outside-, return-, and exhaust-air dampers. b. Conditions of filters. c. Cooling coil, wet- and dry-bulb conditions. d. Face and bypass damper settings at coils. Testing, Adjusting and Balancing for HVAC Central Chilled Water Plant and Cooling Tower Design Section